Electrical diagrams, Schematic - complete machine, Power wave 450 – Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B User Manual

Page 271

ELECTRICAL DIAGRAMS

G-3

POWER WAVE 450

SCHEMATIC - COMPLETE MACHINE

7-21-95E

380-415V

440-460V

CR1

TP4

TP5

TP6

POS

NEG

(24V)

(42V)

(115V)

AC2

L1A

L3A

(24V)

326

324

321

323

AC1

AC3

TO A SYSTEM GROUND PER

NATIONAL ELECTRICAL CODE.

NOTES :

N.A. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED

CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON
CODE NUMBER.

D7 THRU D14 OUTPUT DIODES ARE A MATCHED SET.

N.C. C1, C2, C3, C4 CAPACITORS ARE A MATCHED SET.

THE INTERCHANGEABILITY OF A COMPLETE BOARD,

(440-460)

(200-208)

(220-230)

(380-415)

200-208V

220-230V

N.B. D1 THRU D6 OUTPUT DIODES ARE A MATCHED SET.

D15 THRU D20 OUTPUT DIODES ARE A MATCHED SET.

12D

407

408

406

405

12C

402

401

12A

404

403

12B

12A

12B

12A

12B

12C

12D

L1A

11J30

16J30

1J30

6J30

SOFT START

RELAYS

125/40

4J32

6J32

324

326

1J32

3J32

1J31

10J31

12J31

14J31

12K

12J

12K

12J

POS

NEG

RUN MODE

24VAC

0VAC

1J40

9J40

3J40

11J40

6J40

14J40

8J40

16J40

1J41

9J41

10J41

2J41

7J41

15J41

16J41

24V

42V

PROTECTION BOARD

2J39

3J39

4J39

3J36

4J36

1J36

2J36

361

362

(+)

(-)

361

362

4 PRIMARY LEADS 1T,1B,4T,4B
ARE FEEDED THRU CURRENT TRANSFORMER

CURRENT TRANSFORMER

3J50

1J50

6J50

4J50

Iout

SHUNT BOARD

7J62

4J62

2J62

499

467

11J60

1J62

DIVIDER

BUFFER

2.7/10

.047/1200

320V 160J

.047/400

320V 160J

6J62

SNUBBER BOARD

203

204

205

208

203

205

208

CONTROL BOARD

PROTECTION BOARD

POWER BOARD

< 25uS

50uS

D1-D6

INPUT RECTIFIER

380-460V

208-230V

25/25

R10

7.5K/25

3500uF

450V

.047/1200

SWITCH BOARD #3

(LEFT TOP)

(LEFT BOTTOM)

SWITCH BOARD #4

3500uF

450V

.047/1200

25/25

7.5K/25

3500uF

450V

.047/1200

SWITCH BOARD #1

(RIGHT TOP)

(RIGHT BOTTOM)

SWITCH BOARD #2

25/25

3500uF

450V

.047/1200

R11

40/100

ELECTRODE

WORK

MACHINE SCHEMATIC

(ON OUTPUT RECTIFIER ASBLY)

POWER SWITCH

OFF

ELECTRICAL SYMBOLS PER E1537

204

8J41

L3A

461

462

464

TOP
FAN

BOTTOM

FAN

RECONNECT PANEL

1J19

2J19

3J19

4J19

5J19

6J19

7J19

8J19

9J19

10J19

11J19

12J19

13J19

14J19

15J19

16J19

1J18

2J18

3J18

4J18

5J18

6J18

7J18

8J18

9J18

10J18

LCD DISPLAY

KEYPAD

ISOLATED

CIRCUIT

ISOLATED

CIRCUIT

261

262

265

266

263

264

1J26

2J26

5J26

6J26

3J26

4J26

1J14

2J14

5J14

4J14

6J14

3J14

277

276

275

4J10

5J10

1J10

3J10

8J10

9J10

277

276

275

111A(R)

112A(W)

117A(R)

118A(W)

112A(W)

117A(R)

118A(W)

111A(R)

1J27

4J27

1J28

4J28

167A

8J60

15J60

9J60

13J60

121A

221A

121A

221A

32B

32C

32D

32E

42B

42C

31B

31C

102B

105A

102D

106A

31B

31C

32B

32D

42B

42C

32C

32E

8J34

12J34

10J34

13J34

1J34

5J34

3J34

6J34

102B

105A

102D

106A

11J34

14J34

4J34

7J34

D
E

102C
177A
176A
175A

A
B
C

7J93
5J93
2J93

3J93
4J93

293

296

294

291

292

294

291

292

10J10

6J10

7J10

(24V)

(42V)

(115V)

(24V)

(440-460)

(200-208)

(220-230)

(380-415)

WATER COOLER

3J3

4J3

5J3

6J3

453

454

455

456

453

454

455

456

1J11

3J11

7J11

8J11

2J12

4J12

4J13

2J13

24V

374

371

372

373

24V

WF2 TRIGGER

WF1 TRIGGER

WF2

TRIGGER

1.5V=CLOSE

TRIGGER

1.5V=CLOSE

WF1

371

374

372

373

1J37

4J37

3J37

2J37

24VAC WHEN
WF2 TRIGGER

1J15

2J15

PIEZO

BUZZER

300

301

10J16

1J16

9J16

6J16

7J16

2J16

3J16

8J16

447

448

446

444

449

443

442

445

ELECT.VOLT.FEEDBACK

WF1 ARC VOLT.FEEDBACK

WF2 ARC VOLT.FEEDBACK

WF1 WORK VOLT.FEEDBACK

WF2 WORK VOLT.FEEDBACK

202

206

201

207

8J20

5J20

4J20

3J20

2J20

6J20

1J20

7J20

202

206

201

207

6J61

10J61

7J61

8J61

1J61

5J61

2J61

9J61

ELECT.VOLT.FEEDBACK

WF1 ARC VOLT.FEEDBACK

WF2 ARC VOLT.FEEDBACK

WF1 WORK VOLT.FEEDBACK

WF2 WORK VOLT.FEEDBACK

WF1 RECEPTACLE

WF2 RECEPTACLE

8J21

3J21

6J21

2J21

1J21

5J21

211

215

213

216

212

218

237

236

235

5J23

6J23

DISPLAY BOARD

234

232

233

4J23

2J23

3J23

234

232

233

9J42

7J22

227

221

1J22

5J42

223

226

224

225

10J22

6J22

11J22

12J22

10J42

6J42

11J42

12J42

FROM POWER BD.

5J22

4J22

5J44

4J44

10J44

11J44

6J44

12J44

3J44

2J44

8J44

447

448

444

449

443

442

9J44

446

445

(+)

(-)

211

215

H1B

H1A

H2 H2A

H3 H3A

H4 H4A

H5 H5A

H5A

H4A

H3A

H2A

H1A

"A"

321B

321A

321B

321A

POWER WAVE

2990

P73

P70

P71

334

333

336

6J33

3J33

4J33

1J33

32A

CB
5A

MAIN CHOKE

302
306

303
307

1J17

7J17

4J17

8J17

2J17

9J17

4
5
6
7
8

RS232

CONNECTOR

DEAD TIME

5J4

2J4

2J38

3J38

293

296

115V

(+)CAP3,4

(-)CAP1,2

24VAC TO DISPLAY BD. WHEN TRIGGER CLOSE

AC VOLTAGE FROM CT

RECTIFIED CT VOLT. TO CONTROL BD.

CAP.VOLT. & OUTPUT DISABLE SIGNALS TO CONTROL BD.

CAP.VOLTAGE

SENSING CIRCUIT

351

356

1J35

6J35

3J43

1J43

42VAC SUPPLY, FROM PROTECTION BD.

0 VAC,FROM 1J33

42VAC,FROM 3J33

42V,FROM 3J33

0VAC,FROM 1J33

115VAC,FROM 6J33

0VAC,FROM 1J33

24VAC,FROM 4J33

24VAC WHEN WF1

TRIGGER CLOSE,TO 4J37

115VAC,FROM 6J33

0VAC,FROM 1J33

42VAC,FROM 3J33

0VAC,FROM 1J33

24VAC,FROM 4J33

24VAC WHEN WF2
TRIGGER CLOSE,TO 2J37

24VAC SUPPLY

FOR

PROTECTION BD.

TO WF1 RECEPTACLE

TO WF2 RECEPTACLE

PROTECTION BD.

GND

+15 Vb

+5 Vb

-5 Vb

-8 Vb

+5 Vc

PWR_DN

ISOLATED DC SUPPLIES,TO DISPLAY BD.

FET GATE SIGNALS TO SWITCH BOARDS #1 & #2

FET GATE SIGNALS TO SWITCH BOARDS #3 & #4

+18 Vd

+15 Va

-15 Va

+5 Va
a_GND

ISOLATED DC SUPPLIES

40mA CURRENT SOURCE

e_GND

+18 Vd

+15 Va

FET BANK B

DRIVER

+15 Va

DRIVER

FET BANK A

NOISE_GND

+15 Va

-15 Va

SHUNT CURRENT
FROM SHUNT BD.

( 5mA AT 400A WELDING CURRENT)

DC SUPPLIES TO SHUNT BD.

RECTIFIED CT VOLT. (+)

RECTIFIED CT VOLT. (-)

OUTPUT DISABE

NOISE_GND

40mA

COUPLED TO 3J26

COUPLED TO 1J27

TRIGGER
CIRCUIT

+15 Va

-15 Va

+5 Va

40mA

TO 4J22

FROM 4J28

DC SUPPLIES TO SNUBBER BD.

TO SNUBBER BOARD

-15 Va

+15 Va

TO SNUBBER BOARD

ISOLATED DC SUPPLIES FROM POWER BOARD

+15 Vb

+5 Vb

-5 Vb

-8 Vb

DISPLAY BD.GND

+5 Vc

(RS232)

GRS232

PWR_DN
(XIRQ)

(+)

(-)

15V

WHEN WF1 TRIGGER

WHEN WF2 TRIGGER

PRESSURE

(+)

(-)

15 V

WATER COOLER CONTROL

POT.WIPER

POT.MAX

POT.MIN

FOOT AMPTROL REMOTE CONTROL

WIRE FEEDER REMOTE CONTROL

10V

WIPER

WF1

WF2

5 Vc (RS232)

GRS232

RX
TX

GND

SERIAL

COMM.

ARC & WORK VOLTAGES TO SNUBBER BD.

GROUND PLANE #1

GROUND PLANE #2

c_GND

b_GND

SHUNT CURRENT TO CONTROL BD.

SNUBBER BD.

GND

.0047/400

10/2

.0047/400

10/2

+15 Va

-15 Va

SHUNT BD.GND

SHUNT BD.

GND

DC SUPPLIES FROM CONTROL BD.

FROM CONTROL BD.

+15 Va

-15 Va

NOISE_GND

ARC & WORK VOLTAGES FROM WIRE FEEDER RECEPTACLES

TERMINAL STRIP

(N.D.)

FOOT AMPTROL RECEPTACLE

(REMOTE)

105B

4J92

1J92

2J92

3J92

6J92

P81

P83

P82

FOOT AMPTROL TRIGGER

5V=OPEN

OR FOOT AMPTROL

24VAC TRIGGER VOLTAGES

+5 Vb

+5Vb

TRIGGER 24V, 42V, & 115V FROM PROTECTION BD.

115V

42V

(N.E.)

SERIAL LOOP COMMUNICATION
FOR WIRE FEEDERS

SWITCH BD.

TSTAT

FREQ.MODULATED

CAP.DIFFERENTIAL VOLT.

FET BANK B

GATE SIGNAL

SERIAL LOOP

CURRENT

FET BANK A

GATE SIGNAL

FREQ.MODULATED

DIFFERENTIAL CAP.VOLT.

OUTPUT DISABLE

NOISE_GND

(1250Hz WHEN CAP.BALANCED)

(OV = RUN

5V = DISABLE)

24VAC WHEN FOOT AMPTROL
CLOSE,TO 4J37

24VAC FROM 4J33

(N.E.)

F1 5A

SLOW BLOW

FUSE

FEEDED

THRU CT

OUTPUT
RECTIFIER

FLYBACK

D7-D14 IN PARALLEL

IN PARALLEL

FEEDED
THRU CT

FEEDED

THRU CT

FEEDED

OUTPUT

RECTIFIER

D15-D20

IN PARALLEL

N.D. NOT EXIST ON MACHINE WITHOUT WATER COOLER
N.E. NOT EXIST ON PW350 & PW500

FROM CONTROL BD.

FEEDBACK VOLTAGES

TO CONTROL BD.

FEEDBACK VOLTAGES FROM SNUBBER BD.

OUTPUT RECTIFIER

TSTAT

AUXILIARY TRANSFORMER #2

SHUNT CURRENT FROM SHUNT BD.

24VAC WHEN WF1 OR

FOOT AMPTROL TRIGGER CLOSE

AUXILIARY TRANSFORMER #1

DC SUPPLIES

MAIN TRANSFORMER LEFT SIDE

MAIN TRANSFORMER RIGHT SIDE

(Io = 5mA AT 400A WELDING CURRENT)

213

216

212

218

G-3

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.